Apparatus for pushing conductors into conduit and other structures

ABSTRACT

An apparatus and methods for pushing conductors into conduit and other structures are disclosed. The apparatus (“pusher”) can include rollers to apply a pushing force to one or more conductors or bundles of conductors. One or more rollers can be coupled to a drive mechanism. The pusher is configured to pull conductors or bundles of conductors off of one or more spools, and push the conductors or bundles of conductors without de-bundling or sorting the conductors. The conductors can be fed through the pusher in any format including side-by-side, vertical on top of one another, twisted together, or other formats. The pusher can include a guiding device that is configured to route the conductors from the pusher to a conduit through which the conductors are being pushed or pulled.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 16/429,390 filed Jun. 3, 2019, entitled “Apparatusfor Pushing Conductors into Conduit and Other Structures,” now U.S. Pat.No. 11,451,019, which is incorporated by reference herein in itsentirety; and which is a continuation of and claims priority to U.S.patent application Ser. No. 15/784,666 filed Oct. 16, 2017, entitled“Apparatus for Pushing Conductors into Conduit and Other Structures,”now U.S. Pat. No. 10,312,671, which is incorporated by reference hereinin its entirety; and which is a continuation of and claims priority toU.S. patent application Ser. No. 13/785,496 filed Mar. 5, 2013, entitled“Apparatus for Pushing Conductors into Conduit and Other Structures,”now U.S. Pat. No. 9,793,690, which is incorporated by reference hereinin its entirety; and which is a continuation of and claims priority toU.S. patent application Ser. No. 12/767,214 filed Apr. 26, 2010 entitled“Apparatus for Pushing Conductors Into Conduit and Other Structures,”now U.S. Pat. No. 8,408,520, which is incorporated by reference hereinin its entirety.

BACKGROUND

The present disclosure is directed to methods and apparatuses forpushing conductors. More particularly, the present disclosure isdirected to a pusher for pushing conductors into conduit and otherstructures.

Electrical needs of modern facilities such as houses, apartmentbuildings, warehouses, manufacturing facilities, office buildings, andthe like, have increased as the use of electrical devices has increased.During construction of many buildings, particularly commercial space,conduit is often run between electrical panels and anticipated powerconsumption sites to comply with various building codes and/or forsafety or efficiency considerations. Conductors are typically pulledthrough the conduit after the conduit is in place.

Special tools exist for pulling conductors through conduit includingwire pullers and other devices. In practice, a rope or wire is oftenthreaded through a conduit, and a number of conductors are attached tothe rope or wire with tape or other attachment mechanisms. The rope ispulled back through the conduit with the conductors attached thereto,thus pulling one end of the conductors to a desired location. Typically,manpower is needed on both ends of the conduit during a conductor pull;one or more people to pull the conductors, and one or more people tofeed the conductors into the conduit to prevent tangling, snagging,and/or other damage to the conductors. Due to the increasing electricalneeds of modern homes and businesses, pulling conductors through conduitis a time consuming and labor intensive task that may occupy a growingpercentage of construction projects.

It is with respect to these and other considerations that the disclosuremade herein is presented.

SUMMARY

The present disclosure is directed to an apparatus for pushingconductors into conduit and other structures. The apparatus (“pusher”)can include a drive roller and one or more rollers for cooperating withthe drive roller to apply a pushing force to one or more conductors orbundles of conductors. The drive roller can be coupled to a drivemechanism such as a motor and gearbox. One or more of the rollers can beconnected to the drive roller with a chain, belt, gears, or othermechanisms such that the one or more rollers are powered by the drivemechanism as well.

The pusher is configured to pull conductors or bundles of conductors offof one or more spools, and push the conductors or bundles of conductorswithout de-bundling or sorting the conductors. The conductors can be fedthrough the pusher in any format including side-by-side, vertical on topof one another, twisted together, or other formats. Additionally, thepusher is configured to grip conductors of varied sizes and with variedcoatings including small gauge conductors, and “no-lube” conductors thatare impregnated or coated with lubrication. The pusher is furtherconfigured to push conductors with or without a pulling rope attached tothe conductors.

The pusher can include a guiding device that is configured to route theconductors from the pusher to a conduit through which the conductors arebeing run, i.e., pushed or pulled. The guiding device can include aninlet, a tube, and an outlet. The tube can be flexible or semi-rigid,and can route the conductor into a conduit without requiring manpowerbetween the pusher and the conduit. The pusher can also include remotecontrols for controlling one or more pushers and pullers simultaneouslyto accommodate various safety and efficiency considerations.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to be used to limit the scopeof the claimed subject matter. Furthermore, the claimed subject matteris not limited to implementations that solve any or all disadvantagesnoted in any part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram schematically illustrating a conductor pusher,according to exemplary embodiments.

FIG. 2 is an isometric drawing illustrating a conductor pusher,according to an exemplary embodiment.

FIG. 3A is a plan drawing illustrating a top view of the bottom portionof the conductor pusher illustrated in FIG. 2 , according to anexemplary embodiment.

FIG. 3B is a plan drawing illustrating a bottom view of the top portionof the conductor pusher illustrated in FIG. 2 , according to anexemplary embodiment.

FIG. 4 is a side elevation drawing illustrating a front view of theconductor pusher of FIG. 2 , according to an exemplary embodiment.

FIGS. 5A-5C are schematic illustrations showing roller configurationsand conductor paths, according to exemplary embodiments.

FIG. 6 is a perspective drawing illustrating an inlet of a guidingdevice, according to an exemplary embodiment.

FIG. 7 is a schematic block diagram illustrating an operatingenvironment for using the pusher, according to an exemplary embodiment.

DETAILED DESCRIPTION

The following detailed description is directed to methods, systems, andapparatuses for pushing conductors through conduit and other structures.This description provides various components, one or more of which maybe included in particular implementations of the systems and apparatusesdisclosed herein. In illustrating and describing these variouscomponents, however, it is noted that implementations of the embodimentsdisclosed herein may include any combination of these components,including combinations other than those shown in this description.

FIG. 1 is a block diagram schematically illustrating a conductor pusher100, according to an exemplary embodiment. In the illustratedembodiment, the pusher 100 includes one or more hardware components(“hardware”) 102, one or more software components (“software”) 104, oneor more network interfaces 106, and one or more control modules 108. Thehardware 102 can include hardware components of the pusher 100. As willbe explained below with reference to FIGS. 2-7 , the hardware 102 caninclude, but is not limited to, one or more rollers, one or more drives,any number of guides, dividers, height/tension adjustment mechanisms,supports, guiding devices, gears, chains, and/or other hardware. Thesoftware 104 can include software components of the pusher 100. Thesoftware 104 can include, but is not limited to, applications, routines,subroutines, programs, computer-readable instructions,computer-executable instructions, and the like, for controlling variousfunctions of the pusher 100.

The network interface 106 can be operatively linked and in communicationwith one or more communications networks such as, for example, privatenetworks, the Internet, cellular communications networks, wireless areanetworks, an intranet, other networks, combinations thereof, and thelike. The network interface 106 can be used to communicate with otherdevices and/or networks. It should be understood that the pusher 100 canbe configured to communicate any desired information to another devicevia the network interface 106. In some embodiments, the networkinterface 106 includes a wireless transmitter for communicating with aremote control with which an operator controls the pusher 100. It shouldbe understood that this embodiment is illustrative, and that the remotecontrol can communicate with the pusher 100 via hardware other than thenetwork interface 106.

The control module 108 can be used to control the functions of thepusher 100. The control module 108 can include one or more processors110, which can be operatively linked and in communication with one ormore memory devices (“memory”) 112 via one or more data/memory busses114. The processor 110 can execute computer-readable instructions storedin the memory 112. Execution of the computer-readable instructions cancause the pusher 100 to perform various functions, for example, thefunctionality of the pusher 100 described herein. Although the controlmodule 108 is illustrated as a separate entity, with respect to thehardware 102 and the software 104, it should be understood that thefunctions described with respect to the control module 108 can beperformed by the hardware 102 and the software 104. For example, thehardware 102 can include a memory and a processor, and the software 104can include applications 116 and other data 118 illustrated in thememory 112. As such, it must be understood that the illustratedconfiguration is exemplary, and is described in the presented manner forease of description.

The words “memory” and “storage device,” as used herein collectivelyinclude, but are not limited to, processor registers, processor cache,random access memory (RAM), other volatile and non-volatile memorydevices, semi-permanent or permanent memory types; for example,tape-based media, optical media, flash media, hard disks, combinationsthereof, and the like. While the memory 112 is illustrated as residingproximate to the processor 110, it should be understood that the memory112 can be a remotely accessed storage system, for example, a serverand/or database on a communications network, a remote hard disk drive, aremovable storage medium, a database, a server, an optical media writer,combinations thereof, and the like. Moreover, the memory 112 is intendedto encompass network memory and/or other storage devices in wired orwireless communication with the pusher 100, which may utilize thenetwork interface 106 to facilitate such communication. Thus, any of thedata, applications, and/or software described below can be stored withinthe memory 112, the software 104, and/or accessed via networkconnections to other data processing systems (not shown) that mayinclude a local area network (LAN), a metropolitan area network (MAN), awide area network (WAN), and the like, for example.

The applications 116 can include various programs, routines,subroutines, algorithms, software, tools, and the like (“instructions”),for operating the pusher 100; calibrating various components of thepusher 100; tuning one or more drive mechanisms of the pusher 100;adjusting the speed of the pusher 100; safety applications and controlsof the pusher 100; reporting and recording modules; and the like, aswell as programs or applications to make the pusher 100 operable toperform any of the functions described below. The applications 116 alsocan include instructions used to operate the pusher 100 and/or devicesconnected to the pusher 100, if any. The instructions can include, forexample, operating systems, firmware, drivers for peripherals, and thelike. The other data 118 can include, for example, usage data andstatistics, other programs or software, and the like.

While the above description of the pusher 100 has described variousforms of computer executable instructions, e.g., the software 104 andthe applications 116, it should be understood that the software 104and/or applications 116 can be omitted, and that the pusher 100 can becontrolled by one or more hardware controls. In some embodiments, forexample, the pusher 100 is controlled by a power switch or a variabledrive switch. These examples are illustrative, and should not beconstrued as being limiting.

Turning now to FIG. 2 , an exemplary embodiment of the pusher 100 willbe described. The pusher 100 includes a top portion 200 and bottomportion 202. In some embodiments, the top portion 200 and the bottomportion 202 include a top frame and a bottom frame, respectively. Thetop portion 200 and/or the bottom portion 202 may be formed from anysuitable material including, but not limited to, steel, aluminum, carboncomposite, or other materials. It should be understood that the topportion 200 and the bottom portion 202 can be solid structures, andtherefore may be configured as substantially planar structures.Additionally, or alternatively, the top portion 200 and the bottomportion 202 can include a frame with a plate, grid, fencing, or othermaterial, if desired, which can reduce the total weight and/or cost ofthe pusher 100. In the illustrated embodiment, the top portion 200 is aframe with a grid panel disposed at the top layer to protect a user frommoving parts. In the illustrated view, however, the grid panel has beenremoved for allowing a clear view of the pusher 100. This view is merelyexemplary, and should not be construed as being limiting in any way.

The bottom portion 202 includes a drive roller 204 coupled to a drive206. In some embodiments, the drive 206 includes a motor and a gearbox,though other structures are contemplated. The motor and the gearbox ofthe drive 206 can be selected and sized according to desired performancecharacteristics, preferences, and/or requirements. Thus, the drive 206can include any desired motor type and design, and can be sizedaccording to any desired considerations. Similarly, the gearbox caninclude a worm gear, a transmission, or other gears. The gearbox can beselected and sized according to anticipated needs, loads, and/orapplications. In some embodiments, the components of the drive 206 areselected to provide the pusher 100 with high-torque, high-speed feedcapabilities. It should be understood that the above embodiments areexemplary.

The bottom portion 202 also can include rollers 208A and 208B, which maybe coupled to the drive roller 204 via one or more chains, belts, gears,combinations thereof, and the like (not illustrated in FIG. 2 ). Thedrive roller 204 and the rollers 208A, 208B can cooperate with rollers208C and 208D on the top portion 200 to provide the functionalitydescribed herein. It should be understood that none, some, or all of therollers 208A-D can be coupled to additional motors or other drivemechanisms, and can be coupled to the drive 206 and the drive roller204, if desired. In some embodiments, one or more of the drive roller204 and the rollers 208A-D are grooved rollers, as will be explainedbelow.

The rollers can be formed from metal, plastic, rubber, other materials,and/or combinations thereof. In one embodiment, the drive roller 204 andthe rollers 208A, 208B are six-inch grooved rollers on eight-inchcenters with a one-inch shaft, and are connected to the bottom portion202 using pillow block bearings. In some embodiments, the rollers 204,208A-D are designed to accommodate conductors of various gauges, toaccommodate a number of conductors in a bundle or arranged side-by-side,and/or to accommodate “no lube” conductors. For example, grooves 209 ofa grooved roller design can be employed to allow the pusher 100 to gripthe “no lube” conductors and/or conductors of various gauges.Additionally, the grooves 209 of the grooved roller design can beemployed to allow the pusher 100 to simultaneously feed multipleconductors of various gauges, which may be oriented in bundles and/orarranged side by side.

The rollers 208C, 208D can be six-inch profiled rollers on 8-inchcenters with a one inch shaft, and are connected to the top portion 200using pillow block bearings. The rollers 208C, 208D are arranged on thetop portion 200 such that the roller 208C is centered in a gap betweenthe drive roller 204 and the roller 208A, and the roller 208D iscentered in a gap between the rollers 208A and 208B. This arrangement isillustrative, and should not be construed as being limiting in any way.The rollers 204, 208A-D can be arranged and/or configured in variousarrangements and configurations depending upon the desired performancecharacteristics. Some exemplary roller configurations are illustratedbelow with reference to FIGS. 5A-5C.

The pusher 100 and/or the drive 206 thereof can be controlled by acontroller 210. The controller 210 can include, or can be substitutedby, the functionality of the control module 108 described above withreference to FIG. 1 . Additionally, the controller 210 can include amaster power switch, a safety lock, a variable drive control switch, aplug for insertion in a power outlet or other power source, and/or othercontrols (not illustrated). The controller 210 can be linked and/or incommunication with the drive 206, and can be used to activate,deactivate, enable, and disable the drive 206, if desired.

The pusher 100 can include supports 212A, 212B for supporting the topportion 200 and/or for joining the top portion 200 to the bottom portion202. In some embodiments, the top portion 200 couples to one or more ofthe supports 212A, 212B via one or more sleeves, plates, and/or lockselector mechanisms 214A, 214B. In the illustrated embodiment, thesupports 212A, 212B are formed from steel, and a number of through holes216 are formed in the supports 212A, 212B. In some contemplatedembodiments, sleeves are formed on the top portion 200. The sleeves canbe configured to slide over and/or down the supports 212A, 212B, and caninclude one or more apertures. The lock selector mechanisms 214A, 214Bcan include cotter pins, hitch pins, R-clips, linchpins, bolts, screws,rivets, nails, and/or other mechanisms that can interface with thesupports 212A, 212B. In some embodiments, the lock selector mechanisms214A, 214B are hitch pins that pass through the apertures in the sleevesand/or a plate connected to the top portion 200, and through the throughholes 216. The lock selector mechanisms 214A, 214B are locked to holdthe top portion 200 in a desired position.

The top portion 200 and/or the bottom portion 202 also can includeguides 218 (illustrated on the bottom portion 202 in FIG. 2 ). Theguides 218 can be used to guide conductors into the rollers 204, 208A-Dand/or to guide the conductors out of the rollers 204, 208A-D to preventthe conductors from contacting any structure outside of the area boundby the guides 218. The guides 218 can help prevent the conductors fromgetting tangled, cut, snagged, or otherwise damaged during feeding orpushing. The guides 218 can be formed from any desired materials and inany desired configuration. In some embodiments, the guides 218 includerollers. The rollers can be formed from steel, rubber, plastic, carboncomposite, aluminum, or other materials. In some embodiments, therollers are formed from ESD-safe plastics and bearings to reduce therisk of electrostatic discharge (“ESD”) in facilities handlingESD-sensitive goods. These examples are illustrative.

The pusher 100 also can include a height/tension adjustment mechanism220 for adjusting the distance and/or tension between the top portion200 and the bottom portion 202. In some embodiments, adjustment of thedistance/tension between the top portion 200 and the bottom portion 202also adjusts the distance/tension between the rollers 204, 208A, 208B atthe bottom portion 202 and the rollers 208C, 208D at the top portion200. It should be appreciated that in some embodiments, the entire topportion 200 is moved along the supports 212A, 212B to adjust thedistance between the top portion 200 and the bottom portion 202. In someembodiments, the height/tension adjustment mechanism 220 may be usedsolely for adjusting the tension between the rollers 204, 208A-D.

The distance between the rollers 204, 208A, 208B and the rollers 208C,208D can be adjusted to accommodate one or more conductors of variousdiameters and/or bundles of conductors, the speed at which theconductors or bundles of conductors are pushed through the pusher 100,the amount of slippage between the conductors or bundles of conductorsand the rollers 204, 208A-D, and for other purposes. It should beunderstood that the rollers 204, 208A-D further may include positionadjustment mechanisms to allow users to adjust the horizontal and/orvertical position of one or more of the rollers 204, 208A-D.

The height/tension adjustment mechanism 220 can include any suitablestructures for adjusting the distance/tension between the top portion200 and the bottom portion 202. In some embodiments, the height/tensionadjustment mechanism 220 includes a rod or threaded screw (“rod”) 222that passes through a plate 224 on the top portion 200, and engages asleeve or threaded nut (“sleeve”) 226 on the bottom portion 202. In theillustrated embodiment, the rod 222 includes a handle 228 for turningthe rod 222, and thereby adjusting the tension between the top portion200 and the bottom portion 202. In some embodiments, the sleeve 226 isreplaced with a plate, and the rod 222 is replaced with a stow bolt orother threaded bolt. The tension between the top portion 200 and thebottom portion 202 may be adjusted by a wing nut or other device placedon the threaded portion of the stow bolt. These examples areillustrative, and should not be construed as being limiting in any way.

The pusher 100 also can include casters 230. In some embodiments, thecasters 230 are inflatable tires. The pusher 100 can include feet orstands in addition to, or instead of, the casters 230. The pusher 100also can include a handle 232 for moving, bracing, and/or towing thepusher 100.

In some embodiments, the pusher 100 includes a guiding device 234. Theguiding device 234 includes a body (“tube”) 236. The tube 236 can berigid, semi-rigid, or flexible. In the illustrated embodiment, the tube236 is a flexible tubular structure formed from galvanized steel oraluminum, though other materials and degrees of rigidity arecontemplated. The guiding device 234 includes an inlet/throat portion238 (“inlet”) through which pushed conductors enter the guiding device234. In some embodiments, the inlet 238 is formed with dimensions thatare substantially similar to the tube 236. In some embodiments, theinlet 238 has a first diameter at one end and a second diameter at asecond end. Thus, the inlet 238 may be funnel- or nozzle-shaped, ifdesired. In the illustrated embodiment, a leading edge 240 of the inlet238 is formed as a smooth edge to prevent snagging, tearing, ripping,bending, or otherwise damaging conductors being passed into or throughthe guiding device 234. The inlet 238 is illustrated and described inmore detail below with reference to FIGS. 6A-6B.

The guiding device 234 also includes an outlet portion 242 (“outlet”)through which pushed conductors exit the guiding device 234 and enterinto a conduit (not illustrated), if desired. The outlet 242 can includean outlet assembly 244, which can interface with a conduit. In someembodiments, a conduit guiding device adapter or other suitable device(not illustrated) is used to allow mating between the conduit and theoutlet 242 or outlet assembly 244 of the guiding device. The conduitguiding device adapter can be coupled to a conduit through which theconductor is to be pushed, and the outlet assembly 244 of the guidingdevice 234 can be attached to a conduit guiding device adapter or otherdevice that couples the outlet 242 of the guiding device 234 to an inletportion of the conduit.

The guiding device 234 can be connected to the pusher 100 using anysuitable device. In one embodiment, the guiding device 234 is connectedto the pusher using a chain vise. In other embodiments, the guidingdevice 234 is bolted, welded, or clamped to the pusher 100 or acomponent thereof. These embodiments are illustrative.

As illustrated in FIG. 2 , one or more reels or spools 246 (“spools”) ofconductors 248 can be positioned proximate to the pusher 100. It shouldbe appreciated that the conductors 248 can include one or more bundlesof conductors 248. The conductors 248 can be pre-bundled and wound ontothe spools 246 in bundled form, if desired. Alternatively, conductors248 from two or more spools 246 can be simultaneously fed into thepusher 100. It further should be understood that more than one guidingdevice 234 may be used with the pusher 100. For example, the pusher 100may be used to push two or more conductors 248, bundles of conductors248, and/or combinations thereof. Some of the conductors 248 may bepushed by the pusher 100 into a first guiding device 234, and some ofthe conductors 248 may be simultaneously pushed by the pusher 100 intoanother guiding device. Thus, the illustrated embodiment isillustrative, and should not be construed as being limiting in any way.

In operation, one or more conductors 248 or bundles thereof are fed intoan inlet end 250 of the pusher 100, and passed into or through therollers 204, 208A-D. As will be explained in more detail below withreference to FIG. 7 , some embodiments employ the use of a puller oranother pusher that operates in concert with the pusher 100. Thus, as isgenerally known, a pulling rope can first be pulled through a conduit orother structure through which the conductors 248 are to be pushed, andthe pulling rope can be attached to the conductors 248 and fed through apuller or pusher on the destination end of the conduit. In otherembodiments, no puller or second pusher is used. Regardless of whether apuller or second pusher is used, the conductors 248 can be passed intothe pusher 100 between the guides 218, or two or more conductors 248 canbe passed into the pusher 100, and the guides 218 can be used asdividers between the fed conductors 248.

In some embodiments, the top portion 200 is removed from the pusher orrotated out of position while the conductors 248 are put into positionfor operation of the pusher 100. Thus, although not visible in FIG. 2 ,the top portion 200 can include pivot mechanisms that allow the topportion 200 to rotate. In the illustrated embodiment, the top portion200 includes pivot mechanisms that allow the top portion 200 to rotateabout an axis A. The pivot mechanisms can include pins, rods, hinges,combinations thereof, and the like. The conductors 248, and/or a pullingrope or wire, if used, can be placed in the pusher 100, such that an endof the conductors 248 is extended past the pusher 100. The conductors248 can be manually fed into the guiding device 234, if desired. The topportion 200 can be rotated back into position and the height/tensionadjustment mechanism 220 can be used to adjust the tension of the pusher100. Alternatively, the conductors 248 can be fed into contact withdrive roller 204 and one or more of the rollers 208A-D without removingor rotating the top portion 200.

The drive 206 of the pusher 100 is activated, and the drive roller 204pushes the conductor 248 toward an outlet end 252 of the pusher 100. Itshould be appreciated that the conductors 248 may be fed into the pusherafter the drive 206 is activated, though in some embodiments, this maycause damage to the conductors 248 and may, therefore, be avoided. Thedrive 206 rotates the drive roller 204. As will be explained below inmore detail with reference to FIG. 4 , the drive roller 204 can becoupled to one or more of the rollers 208A-D via chains, belts, gears,and the like, such that the drive 206 also rotates one or more of therollers 208A-D. The force generated by the drive 206 and the driveroller 204 pushes the conductors 248 through the pusher 100 and out theoutlet end 252 of the pusher 100. From the outlet end 252 of the pusher,the conductors 248 can enter the guiding device 234 and proceed into aconduit or other structure through which the conductors 248 are beingfed. As shown in FIG. 2 , the top frame of the top portion 200 can havea top surface 254 and a bottom surface 256, and the bottom frame of thebottom portion 202 can have a top surface 258 and a bottom surface 260.When the conductor 248 is located in the pusher 100 during use, theconductor 248 can be located between the bottom surface 256 of the topportion 200 and the top surface 258 of the bottom portion 202. Thecasters 230 can be located at the bottom surface 260 of the bottomportion 202.

Turning now to FIGS. 3A-3B, additional details of the pusher 100 and thecomponents thereof will be described in more detail. FIG. 3A is a plandrawing illustrating a top view of the bottom portion 202 of the pusher100, according to an exemplary embodiment. FIG. 3B is a plan drawingillustrating a bottom view of the top portion 200 of the pusher 100,according to an exemplary embodiment. Some structures of the pusher 100are not shown or labeled in FIGS. 3A-3B to avoid obscuring theillustrated and described details.

The drive roller 204 and the rollers 208A, 208B are visible. The driveroller 204 can be connected to the bottom portion 202 using any suitablemechanisms. In the illustrated embodiment, the drive roller 204 isplaced onto a drive shaft 302, which is connected to the bottom portion202 by brackets 304A and 304B. The brackets 304A, 304B can includebearings and/or other structures for allowing rotation of the driveshaft 302. The drive shaft 302 passes through the bracket 304B and iscoupled to the drive 206 using any suitable mechanisms. In someembodiments, the drive shaft 302 is coupled to a worm gear (notillustrated) within the drive 206, which in turn is connected to a motor305. This embodiment is exemplary.

The roller 208A is placed onto a shaft 306A, which is connected to thebottom portion 202 by brackets 304C and 304D. The roller 208B is placedonto a shaft 306B, which is connected to the bottom portion 202 bybrackets 304E and 304F. The roller 208C is placed onto a shaft 306C,which is connected to the top portion 200 by brackets 304G and 304H. Theroller 208D is placed onto a shaft 306D, which is connected to the topportion 200 by brackets 304I and 304J.

The bottom portion 202 also can include guides 308 at the outlet end252. In some embodiments, the guides 308 are substantially similar tothe guides 218 at the inlet end 250, which were described above withreference to FIG. 2 . In other embodiments, the guides 308 are notsimilar to the guides 218. The types of structures and/or devices usedfor each of the guides 218 and/or 308 can be a selected based upon anintended purpose, design characteristics, and/or performancerequirements, among other considerations.

The top portion 200 also can include one or more roller guides 310A and310B. The roller guides 310A, 310B can be used to provide a smoothsurface between the conductors 248 and the surfaces of the top portion200 to prevent the conductors 248 from getting cut, snagged, orotherwise damaged during movement through the pusher 100. It should beunderstood that the roller guides 310A, 310B can be replaced by otherstructures, devices, coatings, surface treatments, paints, and the like,and that similar or identical structures may be placed on the bottomportion 202 in addition to, or instead of, the guides 310A, 310B on thetop portion 200.

As mentioned above with reference to FIG. 2 , the top portion 200 alsocan include pivot mechanisms 312A and 312B. The pivot mechanisms 312A,312B are illustrated in FIG. 3B as pins 314A, 314B that are connected tothe top portion 200 via plates 316A and 316B. In some embodiments, thefunctionality of the pivot mechanisms 312A, 312B is provided by hingesthat are connected to the supports 212A, 212B and the top portion 200.In other embodiments, plates or sleeves with apertures are connected tothe top portion 200, and a hitchpin, R-clip, linchpin, or the like, ispassed through the apertures in the plates, through the through holes216 of the supports 212A, 212B, and are secured with a rod, pin, bolt,or the like, to prevent or reduce unwanted movement. Thus, it should beunderstood that the embodiment illustrated in FIG. 3B is exemplary.

Turning now to FIG. 4 , additional features of the pusher 100 will bedescribed in detail. FIG. 4 illustrates a side elevation view of thepusher 100, according to an exemplary embodiment. Some structures of thepusher 100 are not shown or labeled in FIG. 4 to avoid obscuring theillustrated and described details.

In the view illustrated in FIG. 4 , one embodiment of the configurationof the drive roller 204 and the rollers 208A-D can be seen in profileview. In the illustrated embodiment, the drive 206 includes a housingthat obscures the view of the drive roller 204. Thus, the drive roller204 is illustrated with hidden lines.

The drive roller 204 can be connected to the roller 208A by a chain402A, though a belt, gears, pulleys, and/or other mechanisms can be usedin addition to, or instead of, the chain 402A. In the illustratedembodiment, links of the chain 402A interface with cogs of a drive gear404 on the drive roller 204, and cogs of a gear 406A on the roller 208A.Thus, rotation of the drive roller 204 by the drive 206 results inrotation of the roller 208A. In another embodiment, the chain 402A isreplaced with a belt that wraps around pulleys at the drive roller 204and the roller 208A. Other embodiments are contemplated, but will not bedescribed in detail herein for the sake of brevity.

A second chain 402B interfaces with cogs of the gear 406A on the roller208A, and cogs of a gear 406B on the roller 208B. It should beunderstood that the gear 406A can include two sets of cogs, two sets ofpulleys, and the like, to simultaneously accommodate the chains 402A,402B. Additionally, it should be understood that more than one of therollers 204, 208A-D can be coupled to the drive 206, and that more thantwo of the rollers 204, 208A-D can be connected by one or more chains402A, 402B. In one embodiment, for example, the roller 208B is coupledto another drive mechanism (not illustrated), which can be coupled tothe roller 208A and the drive roller 204 with a chain, belt, gears, orthe like. Thus, the drive mechanism and the drive 206 can besynchronized with one another, and can simultaneously power the roller208A.

Although not illustrated in FIG. 4 , it should be appreciated that therollers 208C, 208D can include gears or pulleys that can interface withchains, belts, or gears at the bottom portion 202. Thus, the rollers208C, 208D can be powered by the drive 206 in addition to, or insteadof, the rollers 208A, 208B. Therefore, the illustrated embodiment shouldnot be construed as being limiting in any way.

As shown in FIG. 4 , the rollers 204, 208A-D can cooperate to form aconductor path 408 along which the conductors 248 (FIG. 2 ), or bundlesthereof, are fed. The conductors 248 are fed through the inlet end 250along the conductor path 408, through the rollers 204, 208A-D along theconductor path 408, and out the outlet end 252 along the conductor path408. Exemplary roller paths will be illustrated and described in moredetail below with reference to FIGS. 5A-5C.

As mentioned above, the pusher 100 also can communicate with a remotecontrol 410 via a communication link 412. The remote control 410 caninclude a footswitch or other device for activating the drive 206 of thepusher 100. Although not illustrated in FIG. 4 , it should beappreciated that the remote control 410 can include or can be coupled toone or more safety mechanisms such as weight sensors, safety switches,and the like. Thus, a worker remote from the pusher 100 may be requiredto stand on a weight sensor and activate the remote control 410 before acontrol signal is communicated to the pusher 100.

The communication link 412 can accommodate wired and/or wirelesscommunications protocols, and can occur over one or more networkinterfaces such as the network interface 106 described above. Thecommunication link 412 can thus be provided over-the-air (“OTA”) or viaa wired network and/or direct link. Any suitable wired communicationsprotocols may be used including, but not limited to, TCP/IP, IPv6, MPLS,UDP, combinations thereof, and the like. Similarly, any suitablewireless protocols may be used including, but not limited to, the IEEE802.11x, 802.16, 802.20, 802.16e, and/or 802.15.x standards, i.e., WIFI,WIMAX, Mobile Broadband Wireless Access (MBWA), Mobile WIMAX, andBLUETOOTH standards, as well as signals transmitted via infrared, IrDA,the ECMA-342 and ECMS 352 standards (“near field communications (NFC)”),other RF signals, combinations thereof, and the like.

Turning now to FIGS. 5A-5C, additional features of the pusher 100 willbe described in detail. FIGS. 5A-5C illustrate roller configurations forthe pusher 100, according to exemplary embodiments. It should beunderstood that the illustrated configurations are illustrative of onlysome contemplated embodiments. Thus, the illustrated configurationsshould not be construed as being limiting in any way.

FIG. 5A illustrates a first roller configuration 500A. The rollerconfiguration 500A is substantially similar to the configuration of therollers 204, 208A-D of the pusher 100 as illustrated in FIGS. 2-4 . Asshown in FIG. 5A, one or more conductors 248 or bundles of conductors248 are passed between the rollers 204, 208A-D along a path 502A. Thedrive roller 204 is coupled to the drive 206. When the drive 206 isactivated, the drive roller 204 rotates in the direction R. As explainedabove, none, some, or all of the rollers 208A-D can be coupled to thedrive roller 204, if desired. In the illustrated embodiment, the rollers208A, 208B rotate in the direction R, and the rollers 208C, 208D rotatein the direction R′.

FIG. 5B illustrates a second roller configuration 500B. In the rollerconfiguration 500B, one or more conductors 248 or bundles of conductors248 are passed between rollers 204B-C, 208E-I along a path 502B. Asshown in FIG. 5B, the pusher 100 can include two or more drive rollers204B-C, each of which may be coupled to one or more drives such as thedrive 206. In the illustrated embodiment, the drive roller 204B iscoupled to a first drive (not illustrated), and rotates in the directionR. The drive roller 204C is coupled to a second drive (not illustrated),and rotates in the direction R′. As explained above, none, some, or allof the rollers 208E-I can be coupled to one or more of the drive rollers204B-C, if desired. In the illustrated embodiment, the rollers 208E-Grotate in the direction R′ and the rollers 208H-I rotate in thedirection R.

FIG. 5C illustrates a third roller configuration 500C. In the rollerconfiguration 500C, one or more conductors 248 or bundles of conductors248 are passed between the rollers 204D-E, 208J-M along a path 502C. Asshown in FIG. 5C, the pusher 100 can include two or more drive rollers204D-E, each of which may be coupled to one or more drives such as thedrive 206. In the illustrated embodiment, the drive roller 204D iscoupled to a first drive (not illustrated), and rotates in the directionR′. The drive roller 204E is coupled to a second drive (notillustrated), and rotates in the direction R. As explained above, none,some, or all of the rollers 208J-M can be coupled to one or more of thedrive rollers 204D-E, if desired. In the illustrated embodiment, therollers 208J, 208K rotate in the direction R and the rollers 208L, 208Mrotate in the direction R′.

Turning now to FIG. 6 , additional features of the pusher 100 will bedescribed in detail. FIG. 6 is a perspective drawing illustrating theinlet 238 of the guiding device 234, according to an exemplaryembodiment. As explained above, the inlet 238 can include a leading edge240, illustrated in FIG. 6 as a rim. The inlet 238 also includes athroat 600. In the illustrated embodiment, the throat 600 is tapered sothat a first end 602 of the throat 600 has a first diametersubstantially equal to the inner diameter of the rim, and a second end604 of the throat 600 has a diameter substantially equal to a diameterof the tube 236. A body 606 can be connected to or formed at the secondend 604 of the throat 600, and can connect to the tube 236 of theguiding device 234. The inlet 238 can be formed from a single piece ofmaterial, or can be a composite structure formed from two or morecomponents.

As mentioned above, the guiding device 234 can include an outletassembly 244 that is configured to connect to a conduit. The guidingdevice 234 can be used to eliminate the need for manpower between thepusher 100 and a conduit or other structure into which the conductors248 are fed, or can at least reduce the amount of manpower neededbetween the pusher 100 and a conduit or other structure. In someembodiments, the body 606 connects directly to a conduit instead of thetube 236. Additionally, some or all of the edges of the inlet 238 can besmooth or polished to reduce friction between the surfaces of the inlet238 and the conductors 248 during feeding. Furthermore, the materialsused to form the inlet 238 can be varied to reduce friction, if desired.For example, the inlet 238 can be coated or impregnated with any desiredmaterials to provide reduced friction or for other purposes.

In some embodiments, the inlet 238, the tube 236, and/or the outletassembly 244 includes a lubrication mechanism 608 for applying lubricantto the conductors 248 as the conductors 248 are fed into the tube 236and/or into a conduit (not illustrated). The lubrication mechanism 608supplies a lubricant to one or more spray heads 610 disposed in the body606. Lubricants can be supplied to the spray heads 610 via lubricationlines 612. In some embodiments, the lubrication mechanism 608 receiveslubrication via a supply line 614. The supply line 614 can bepressurized, and/or the lubrication mechanism 608 can include a pump topressurize the lubrication for delivery to the spray heads 610. In someembodiments, the amount of lubrication applied to the conductors 248 issuch that the supply line 614 may be omitted, and the lubricationmechanism 608 can include a self-contained tank for the lubricant. Theseembodiments are exemplary, and should not be construed as being limitingin any way.

Turning now to FIG. 7 , an operating environment 700 for the pusher 100will be described in detail. The pusher 100 is located at a feed end 702of a conduit 704. The pusher 100 pushes one or more conductors 248 intothe conduit 704 via the guiding device 234. As explained above, theguiding device 234 can lubricate the conductors 248, if desired. In someembodiments, the conductors 248 include a “no-lube” coating or sheath,or require no lubrication or “no-lube” coatings. The conductors 248 passthrough the conduit 704 and arrive at a destination 706. In someembodiments, a puller 708 is located at the destination 706. The puller708 can be configured to pull the conductors 248 in concert with thepusher 100. In other embodiments, a second pusher 100 is located at thedestination 706, and is configured to push the conductors 248 onto aspool, into a coil, into a pile, into a second conduit, or elsewhere.

The use of a puller 708 and/or a second pusher 100 at the destination706 can reduce strain and/or stresses on the conductors 248. Forexample, the use of a puller 708 can cause strains or stresses on theconductors 248 when the conductors 248 snag or get caught in the conduit704 or elsewhere. Similarly, the pusher 100 can cause strains orstresses on the conductors 248 during feeding. Thus, a pusher 100 and apuller 708 and/or a second pusher 100 can reduce strains and stresses byapplying a pulling force on one end of the conductors 248 at the sametime as an equal pushing force is applied to another end of theconductors 248. While such benefits are possible in some embodiments, itshould be understood that these benefits are not always recognized as aresult of employing an operating environment similar to that illustratedin FIG. 7 . Thus, the above benefits should not be construed as limitingin any way the scope of the disclosure and/or the claims.

An operator 710 can be located proximate to the destination 706 and/orelsewhere in the operating environment 700. As shown in FIG. 7 , theoperator 710 controls the remote control 410, which sends controlsignals 712 to one or more pushers 100 and/or pullers 708. Thus, thepusher 100 can be used as a “dead man” at a feed end, if desired, andcan be controlled remotely by the operator 710 or another entity. Insome embodiments, the ability to control one or more pushers 100 and/orpullers 708 can provide a safer work environment, and can eliminate theneed for operators on one or more ends of the conduit 704.

The subject matter described above is provided by way of illustrationonly and should not be construed as limiting. Various modifications andchanges may be made to the subject matter described herein withoutfollowing the example embodiments and applications illustrated anddescribed, and without departing from the true spirit and scope of theclaimed subject matter, which is set forth in the following claims.

The invention claimed is:
 1. A conductor pusher that is configured topush a conductor along a conductor path that passes through a portion ofthe conductor pusher and from an inlet end of the conductor pusher to anoutlet end of the conductor pusher, the conductor pusher comprising: abottom portion comprising a first frame, a first support at the inletend, and a second support at the outlet end; a drive roller located atthe bottom portion, wherein the drive roller rotates around a firstshaft that is mounted to a first surface of the bottom portion using afirst pair of brackets; a top portion comprising a second frame, whereinthe top portion is pivotally connected to the bottom portion by a pivotmechanism, and wherein the top portion is rotatable about an axis thatpasses through the pivot mechanism; a motor that drives the driveroller; at least one roller located at the top portion, wherein the atleast one roller cooperates with the drive roller to apply a force tothe conductor to push the conductor through the portion of the conductorpusher, wherein the at least one roller rotates around a second shaftthat is mounted to a second surface of the top portion using a secondpair of brackets; a first pair of guides located at the inlet end,wherein the first pair of guides are attached to the first frame, andwherein the first pair of guides guide the conductor to the portion ofthe conductor pusher; and a second pair of guides located at the outletend, wherein the first pair of guides are attached to the first frame,and wherein the second pair of guides guide the conductor from theportion of the conductor pusher.
 2. The conductor pusher of claim 1,wherein the first frame of the bottom portion comprises a first topsurface and a first bottom surface, and wherein the second frame of thetop portion comprises a second top surface and a second bottom surface.3. The conductor pusher of claim 2, further comprising at least twocasters located at the first bottom surface.
 4. The conductor pusher ofclaim 2, further comprising a tension adjustment mechanism comprising afirst structure located at the bottom portion and a second structurelocated at the top portion.
 5. The conductor pusher of claim 2, whereinthe conductor path is located between the drive roller and the at leastone roller, and wherein the conductor path is located above the firsttop surface and below the second bottom surface.
 6. The conductor pusherof claim 1, wherein the drive roller engages a first side of theconductor, and wherein the at least one roller engages a second side ofthe conductor.
 7. A conductor pusher for pushing a conductor through aportion of the conductor pusher and from an inlet end of the conductorpusher to an outlet end of the conductor pusher, the conductor pushercomprising: a bottom portion comprising a first frame, a first supportat the inlet end and a second support at the outlet end; a drive rollerlocated at the bottom portion, wherein the drive roller rotates around afirst shaft that is mounted to a first surface of the bottom portionusing a first pair of brackets; a top portion comprising a second frame,wherein the top portion is pivotally connected to the bottom portion bya pivot mechanism, and wherein the top portion is rotatable about anaxis that passes through the pivot mechanism; a motor at the bottomportion, wherein the motor drives the drive roller; at least one rollerlocated at the top portion, wherein the at least one roller cooperateswith the drive roller to apply a force to the conductor to push theconductor through the portion of the conductor pusher, wherein the atleast one roller rotates around a second shaft that is mounted to asecond surface of the top portion using a second pair of brackets; afirst pair of guides located at the inlet end, wherein the first pair ofguides are attached to the first frame, and wherein the first pair ofguides guide the conductor to the portion of the conductor pusher; and asecond pair of guides located at the outlet end, wherein the first pairof guides are attached to the first frame, and wherein the second pairof guides guide the conductor from the portion of the conductor pusher.8. The conductor pusher of claim 7, wherein the first frame of thebottom portion comprises a first top surface and a first bottom surface,and wherein the second frame of the top portion comprises a second topsurface and a second bottom surface.
 9. The conductor pusher of claim 8,wherein the drive roller and the at least one roller are arranged topush the conductor through the portion of the conductor pusher along aconductor path that passes between the drive roller and the at least oneroller.
 10. The conductor pusher of claim 8, further comprising at leasttwo casters located at the first bottom surface.
 11. The conductorpusher of claim 7, further comprising: a tension adjustment mechanismcomprising a first structure located at the bottom portion and a secondstructure located at the top portion.
 12. The conductor pusher of claim9, wherein the drive roller engages a first side of the conductor, andwherein the at least one roller engages a second side of the conductor.13. The conductor pusher of claim 12, wherein the conductor path islocated above the first top surface and below the second bottom surface.14. A method comprising: locating a conductor within a conductor pusher;and activating the conductor pusher to push the conductor along aconductor path that passes through a portion of the conductor pusher andfrom an inlet end of the conductor pusher to an outlet end of theconductor pusher, wherein the conductor pusher comprises a bottomportion comprising a first frame, a first support at the inlet end, anda second support at the outlet end, a drive roller located at the bottomportion, wherein the drive roller rotates around a first shaft that ismounted to a first surface of the bottom portion using a first pair ofbrackets, a top portion comprising a second frame, wherein the topportion is pivotally connected to the bottom portion by a pivotmechanism, and wherein the top portion is rotatable about an axis thatpasses through the pivot mechanism, a motor that drives the driveroller, at least one roller located at the top portion, wherein the atleast one roller cooperates with the drive roller to apply a force tothe conductor to push the conductor through the portion of the conductorpusher, wherein the at least one roller rotates around a second shaftthat is mounted to a second surface of the top portion using a secondpair of brackets, a first pair of guides located at the inlet end,wherein the first pair of guides are attached to the first frame, andwherein the first pair of guides guide the conductor to the portion ofthe conductor pusher, and a second pair of guides located at the outletend, wherein the first pair of guides are attached to the first frame,and wherein the second pair of guides guide the conductor from theportion of the conductor pusher.
 15. The method of claim 14, whereinlocating the conductor within the conductor pusher comprises: rotatingthe top portion about the axis; and locating the conductor within theconductor pusher.
 16. The method of claim 15, further comprising:adjusting a tension between the top portion and the bottom portion usingan adjustment mechanism.
 17. The method of claim 14, wherein the firstframe of the bottom portion comprises a first top surface and a firstbottom surface, wherein the second frame of the top portion comprises asecond top surface and a second bottom surface.
 18. The method of claim17, wherein the drive roller engages a first side of the conductor, andwherein the at least one roller engages a second side of the conductor.19. The method of claim 17, wherein the conductor path passes betweenthe drive roller and the at least one roller, and wherein the conductorpath is located above the first top surface and below the second bottomsurface.
 20. The method of claim 17, wherein the conductor pusherfurther comprises at least two casters located at the first bottomsurface.